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I've got a pile of 1/8" shank carbide endmills that I've broken one way or another. Last night I chucked one into my hand drill and rounded the end off with a ceramic belt. I then just press fit it into the end of a scrap piece of 9/16" diameter stainless round that I had laying around, and now...

Well, I just tried your advise, and now instead of a U shaped blade, I have a W shaped blade. :rolleyes:

If you can, get a mill with an R8 compatible spindle. Along with that, you'll need an R8 collet set. I wouldn't recommend getting the cheapest set you can find, but you don't necessarily need the most expensive either. Next you'll want a decent Vise. Get an actual milling machine vise...

There's a good chance yours is single in/ 220 "3 phase" out. Your motor name plate will usually say the phase of the motor. Single to single VFDs do exist, but they're few and far between, and not that great for grinder applications. Of course, you also have DC motors and controls, which will...

Variable speed via a VFD (variable frequency drive) requires a 3 phase motor. The VFD (at least the VFDs we are referring to) uses standard single phase voltage for the input, but outputs a "simulated" 3 phase voltage to drive the motor (220VAC, not 480VAC)

There are similar brands (very likely made in the same factory) on eBay all the time for comparable prices. They're definitely not as "cheap" as they used to be, but nothing is. I'd also keep an eye out on the surplus/used market too. Granted, a 2hp, 3 phase, 56C frame motor is fairly specific...

You're likely not going to find a "turn key" grinder for $1000. You could certainly build one within that budget, though it may take some careful shopping/sourcing of parts. IIRC, the Revolution grinder kit sold by Brian House (housework.us) averages about $1k, though it does require some basic...

Hard to tell from your picture, but those may very well be galvanized. Maybe use them for pattern templates? Can they be used for liners? Maybe? I'd see how readily they rust first. Galvanic corrosion might be an issue down the road.

Ah, I see what you're saying now. Sounds like it's time to modify the circuitry of the Bosch.... ;)

Must have missed this thread the first time around. Good stuff!

I made up a switched outlet box that my Porta-Band plugs into. You could make one for about $15 worth of electrical parts from the hardware store. My saw plugs into the outlet, and a standard switch turns power on or off. I can't remember how I locked my trigger... I think I use a small c-clamp...

Clean and relatively simple. I like it! I agree with jmforge, a swedge would be a nice addition.

You're likely not going to find a metal cutting bandsaw blade sold with more than 24TPI. It will certainly do the job, but again, if you push too hard, you'll start breaking teeth off. Because of how thin 1/16" stock is, the 24TPI will still want to cut pretty aggressively, so just take it...

Just a quick tip on TPI selection: You typically want about 3 teeth in the material at any given time. Otherwise you risk just shearing the teeth right off if you feed too aggressively.

A backer block is basically just something rigid to wrap your sandpaper around. I've used anything from scraps of micarta or G10, to wood, or even files. If you glue a piece of leather or rubber to your backer block and then wrap your paper around that, it'll give the paper a little more give...

You might try clamping a 2x4 into your vise instead, edge up, and then driving a screw through one of your pin holes, to hold your blade blank onto the edge of the 2x4. This will give full support along the length of the blade, and you'll have plenty of room to sand the full length of your blade...

I think John and CD have the main critiques covered. I'd say it looks pretty dang good for a first knife, much less one that's done with minimal tools. You could definitely make some improvements with fit and finish, though slowing things down would take care of a lot of that. On the next...

That's not too terrible. My shop's a bit messy, but it gets the job done. You're welcome whenever you want to make the drive. Just shoot me a message and we'll work it out.

I see you're in Southern Michigan? I'm in Valparaiso, IN. If you're closer to the southwest end, you may not be that far from me. You're welcome to drop by to talk shop and see my grinders.